I have D44 and it's a D44 ARB cover.
When I remove the old cover (ARB also) the bottom bolt of the cover are destroy and I can't remove it because it too worn

 

Sorry, I guess I just got caught by all the D30 talk in post #2 above. Based on the pictures above and how that new cover is overhanging, are you suggesting that when the cover is off, the face of the diff is sheered like this -



Do you have any pictures of the old cover? I just find that incredibly hard to fathom.

 

Listed as JKU in the initial post, not JKUR, and no contradiction that it was not a d30 ... until this morning. I don't feel bad for making the assumption.

 

if the bottom cover bolt is unusable I suggest you get a new housing. The cover will never be able to seal properly without the bottom bolt.. Check out the Mopar Performance D44HD/J8 housing part number P5160036

https://www.allmoparparts.com/sku/p5160036.html

 

there is the pictures of diff opening to be more clear !

First picture is the front diff and second is the rear diff (both dana44)

 

Wow, that is indeed significant. Sorry I doubted you. Seeing how close you are to that lower bolt hole, I think it's time for a new housing/axle of some sort. That really sux! Kinda makes me think that Rancho might have a good design with their cover and integrated skid! Something like that wouldn't help you at this point.

I don't think having something hack weld some monstrosity to the pumpkin would be worthwhile. If you plan on having the jeep a good bit longer, you'd get your money's worth out of a replacement.

 

Haha no problem !
I didn't believe that too when I saw it !

I think I found someone who can rebuild the entire pumpkin like a new one. It will be really less expansive than a new housing.

And yes a front diff skid plate will be a good investment after the reparation !